Partners in progress

2 August 2006



Converter PSG and suppliers Kongskilde and TS Converting Equipment co-operate closely


London based PSG Group, whose new cleanroom facility was featured in our November, 2004, issue, has continued to improve its operational efficiency by installing an advanced Kongskilde waste removal system serving all of its converting machines. In addition to the tangible benefits this has achieved, the installation is representative of the close level of collaboration that exists between PSG and its suppliers. This is typified both by the work with Kongskilde UK - and by the converting company's long standing partnership with slitting machinery supplier TS Converting Equipment.

The new bespoke waste handling system was commissioned last month. It removes continuous edge trim from the various machines in the factory (including the Deacro slitter in the cleanroom), chops it into small pieces for compaction, and conveys these through air ducts to a central collection point.

Kongskilde UK sales manager John Kightley reflects: “Considering the layout, the number of different machines involved, and the types of material thicknesses, it is one of the most diverse systems we have installed. We have used several different items of equipment from our range within the installation.”

The initial waste removal system supplied for the cleanroom slitter two years ago was designed by Kongskilde to extract two-edge trim up to a maximum width of 40mm, 250 micron thick, at a rate of 500m/min. It comprised two 60mm diameter flexible pick-ups feeding through an in-line twin blade Multicutter running at 2,800rev/min. A Multiair 215TR quiet pressure fan provided the air for an ITF100 Venturi to create the suction required to convey the chopped material into a roll-top container positioned under an air separator some 30m away.

Now there are edge trim removal systems for all four of PSG's slitting machines, with provision to connect to a second Deacro slitter planned for eventual installation in the cleanroom.

“We considered the various material parameters and line speeds for each of the machines and designed a specific edge trim removal system for each one,” reveals John Kightley. This was achieved using a computer programme designed by Kongskilde that calculates the required air speed and back pressure of each system, and confirms the most economic and power efficient method for each one.

Three different methods of extraction are used to convey the chopped edge trim waste from the various slitter positions within the factory to a collection area outside. The two KU4000 air separators have been positioned within the roof structure of a small extension to the building which is close to the road, enabling easy access for collection of the waste containers.

A 'through fan' system was selected to convey the material from the existing and proposed Deacro slitters in the cleanroom because of the long conveying distance required. It also generates the largest volume of waste material, due to the fast operating speeds. A Multiair 1075S with an RVS rotary separator operates in conjunction with single cutters on two of the machines handling the lighter gauge materials to convey the waste.

Kongskilde was able to use the initial Multiair it had supplied for the first system at PSG in conjunction with an FVO Venturi and air return to extract the waste from the slitter dealing with the heavier gauge materials. Here it was considered prudent to use a cutter for each of the trims in this application to ensure longer blade life.

Particular attention was paid to operational noise levels for the three systems. In-line silencers are positioned either side of the cutters, and at various points in the system to reduce noise both within the production area and outside at the waste discharge point.

The system was designed into three separate functions so that, in the event of a motor failure, only 30 per of the production would be lost, unlike a centralized system where all production would stop. Kongskilde also provided PSG with detailed three dimensional CAD layout drawings for the three systems that enabled them to be installed by the company's own engineer - saving on the mechanical installation costs.

Since the installation, labour costs associated with waste removal from the factory have been reduced considerably. The introduction of the in-line Multicutters within the trim extraction pipe lines has dramatically reduced the volume of material entering the waste containers. Initial calculations indicate this to be a fifth of the volume compared with continuous edge trim systems conveyed to PE bags adjacent to the slitting machines. This will produce the greatest cost saving, as all waste collected from the factory is charged by volume.

At around £50,000, the new system was a considerable investment for PSG, but the improved working conditions will result in increased production with reduced labour costs which, together with an 80 per cent reduction in waste disposal charges, should soon amortize the investment.

“It's brought us a huge saving,” enthuses managing director Lawrence Gardezi. “Now we have a system for all our machines, it has saved a lot of space in our factory. The total volume of waste material has been halved through being handled much more efficiently. Overall noise levels are also much lower than before, and we have improved cleanliness and safety. We have decreased waste costs, increased productivity, reduced the workforce (we used to employ a full-time cleaner to clean up around the machines), and ensured health and safety compliance.”

He is happy for the waste handling system to serve as a demonstration facility for Kongskilde - “because it is unique. It serves a range of machines, from elderly slitters that are still doing a valuable job to the latest Deacro, and everything in between. Not only the machines, but the types of material they handle are so varied. John has been involved from the beginning and continues to work closely with us. He's always up to the challenge of adapting systems to meet different applications.”

In addition to these latest improvements, PSG has long benefited on the machinery front from the TS Converting Equipment service package, which has enabled it to keep equipment both old and new in good running order. TS provides service and support for all the company's machines, from its 20-year old Cameron winder to the latest Deacro model.

“We have benefited immensely over the years using the Response after sales service,” confirms Lawrence Gardezi. Support was one of the main factors when we chose the Deacro slitter. They cover everything, from knives to software - even for machines that aren't theirs.”

“Technology has improved dramatically over the years,” observes Tim Self, director of TS Converting, “but the fundamental principles of slitting and rewinding are still very similar. Technology, however, has improved the controllability and consistency of machines, and the transfer of that technology on to the older equipment often gives them a new lease of life.”

Available on all Elite Cameron and Deacro products, the Response service contract is said to provide an affordable means for maintaining the machines, maximizing productivity, minimizing downtime and maintaining consistently high levels of quality. It includes: regular servicing and safety inspections; continuous updating of technical and production files; maintaining machine calibration; and discounted spare parts. Telephone and on-line support systems often enable customers to make their own repairs or adjustments immediately.

PSG and Kongskilde have both had close ties with TS Converting/Elite Cameron for many years. Deacro only uses Kongskilde systems on its machines in the USA. “We have just supplied TS with a system for a bespoke slitting machine for another customer, to remove 14 individual trims,” reveals John Kightley.

Lawrence Gardezi concludes: “All three companies co-operate closely. We all have the same philosophy of doing whatever is required, for whoever, and whenever. Kongskilde gave us a system that could cope with this - and the service from TS supports our machinery. Thanks to our competitive capabilities, we have doubled our international business in the last year.”



Contact

PSG Group
Tel: +44 (0)20 7740 9740
Kongskilde UK
Tel: +44 (0)1869 253058
TS Converting Equipment
Tel: +44 (0)1823 283411





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PSG Group
Kongskilde UK
TS Converting Equipment

Tailormade trim pipes lead to chopper motors on old Harnden ... Tailormade trim pipes lead to chopper motors on old Harnden ...
Multicutter in-line on C24 Multicutter in-line on C24
Multiairs, rotary separator, Venturi system and air return Multiairs, rotary separator, Venturi system and air return
Air separators above storage of waste trim Air separators above storage of waste trim
Trim pipe on Deacro C24 in cleanroom Trim pipe on Deacro C24 in cleanroom


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